Multi-field scanning tools in materials handling vehicles

ABSTRACT

A materials handling vehicle comprises an operator compartment, a compartment tower, a multi-field scanning tool, and mechanisms that facilitate movement along a travel plane in a warehouse. The tool establishes a scan field, and, within scan field bounds, an occupancy detection field and an obstacle detection field. Tool scanning hardware is configured to generate the scan field from a point of origin that is elevated relative to the operator compartment and to expand the scan field such that it intersects the operator compartment and extends laterally beyond lateral edges of the operator compartment such that the occupancy detection field falls within the operator compartment, the obstacle detection field falls outside of the operator compartment, and the multi-field scanning tool is configured to indicate the presence of an occupant in the occupancy detection field and obstacles in the obstacle detection field.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application Ser.No. 62/380,145 (CEZ 1619 P), filed Aug. 26, 2016.

BACKGROUND

The present disclosure relates to object detection and, moreparticularly, to materials handling vehicles equipped to detect objectsin and around the vehicle in a warehouse. For the purposes of definingand describing the concepts and scope of the present disclosure, it isnoted that a “warehouse” encompasses any indoor or otherwise coveredfacility in which materials handling vehicles transport goods including,but not limited to, warehouses intended primarily for the storage ofgoods, such as those where multi-level warehouse racks are arranged inaisles, and manufacturing facilities where goods are transported aboutthe facility by materials handling vehicles for use in one or moremanufacturing processes.

BRIEF SUMMARY

According to the subject matter of the present disclosure is a materialshandling vehicle comprising an operator compartment, a compartmenttower, a steering mechanism, materials handling hardware, a vehicledrive mechanism, a user interface, and a multi-field scanning tool. Thesteering mechanism, materials handling hardware, vehicle drivemechanism, and user interface facilitate forward movement of a leadingedge the materials handling vehicle, and materials handled by thematerials handling vehicle, along a travel plane in a warehouse. Themulti-field scanning tool comprises scanning hardware establishing ascan field, an occupancy filter establishing an occupancy detectionfield within the bounds of the scan field, and an obstacle filterestablishing an obstacle detection field within the bounds of the scanfield. The operator compartment is elevated relative to the travel planeand comprises a pair of lateral edges that are at least partiallynon-obstructive to the scan field of the multi-field scanning tool. Thescanning hardware of the multi-field scanning tool is configured togenerate the scan field from a point of origin that is elevated relativeto the operator compartment and to expand the scan field such that itintersects the operator compartment and extends laterally beyond thelateral edges of the operator compartment such that the occupancydetection field established by the occupancy detection filter of themulti-field scanning tool falls within the operator compartment, theobstacle detection field established by the obstacle detection filter ofthe multi-field scanning tool falls outside of the operator compartmentand terminates at the travel plane, and the multi-field scanning tool isconfigured to indicate the presence of an occupant in the occupancydetection field and obstacles in the obstacle detection field.

In embodiments, the obstacle detection field extends beyond each of thelateral edges of the operator compartment. The obstacle detection fieldmay extend at least about 0.1 m beyond each of the lateral edges of theoperator compartment. The multi-field scanning tool may comprise a towerlaser residing on the compartment tower. The tower laser may be orientedto project the scan field downwardly into the operator compartment. Thescan field may be projected downwardly into the operator compartment ata downward projection angle relative to the compartment tower. Thedownward projection angle may be between about 0 degrees and about 20degrees relative to a vertical axis of the compartment tower. The pointof origin from which the scan field is generated may reside on thecompartment tower. The operator compartment may comprise a leading edgealong an operator platform of the operator compartment, opposite thecompartment tower, and a trailing edge along the operator platformproximate the compartment tower, and the scan field intersects theoperator compartment, along the operator platform, between the leadingedge and the trailing edge of the operator compartment. The multi-fieldscanning tool may comprise adjustable downward projection hardware thatis configured to adjust a downward projection angle of the scan fieldand a location at which the scan field intersects the operatorcompartment between the leading edge and the trailing edge of theoperator compartment. A downward projection angle of the scan field maybe between about 0 degrees and about 20 degrees relative to a verticalaxis of the compartment tower, and the location along the operatorplatform at which the scan field intersects the operator compartmentbetween the leading edge and the trailing edge of the operatorcompartment may be skewed towards the leading edge of the operatorcompartment. The location along the operator platform at which the scanfield intersects the operator compartment may be within about 5 cm ofthe leading edge of the operator compartment. The occupancy detectionfield and the obstacle detection field may comprise contiguous portionsof the scan field, or the occupancy detection field and the obstacledetection field may comprise non-contiguous portions of the scan field.The occupancy detection field and the obstacle detection field maycollectively comprise a portion of the scan field.

In accordance with one embodiment of the present disclosure is materialshandling vehicle comprising a steering mechanism, materials handlinghardware, a vehicle drive mechanism, a user interface, a vehicle body,and a multi-field bumper laser assembly. The steering mechanism,materials handling hardware, vehicle drive mechanism, and user interfacefacilitate forward movement of a leading edge the materials handlingvehicle along a travel plane in a warehouse. The multi-field bumperlaser assembly comprises a forward-left scanning laser that ispositioned to direct a forward-left upright laser field from the leadingedge of the materials handling vehicle, a forward-right scanning laserthat is positioned to direct a forward-right upright laser field fromthe leading edge of the materials handling vehicle, an intersectingscanning laser that is positioned to direct an intersecting laser fieldfrom the leading edge of the materials handling vehicle, intersectingthe forward-right upright laser field and the forward-left upright laserfield, and a laser carrier mounted to the vehicle body. The forward-leftscanning laser is pivotally coupled to the laser carrier about aforward-left upright pivot axis, the forward-right scanning laser ispivotally coupled to the laser carrier about a forward-right uprightpivot axis, and the intersecting scanning laser is pivotally coupled tothe laser carrier about an intersecting pivot axis that intersectsrespective planes of the forward-left upright laser field and theforward-right upright laser field. The multi-field bumper laser assemblyfurther comprises forward-left scanning laser adjustment hardwarecoupling the forward-left scanning laser to the laser carrier at aposition that forces the forward-left scanning laser and theforward-left upright laser field to pivot about the forward-left uprightpivot axis upon adjustment, forward-right scanning laser adjustmenthardware coupling the forward-right scanning laser to the laser carrierat a position that forces the forward-right scanning laser and theforward-right upright laser field to pivot about the forward-rightupright pivot axis upon adjustment, and intersecting laser adjustmenthardware coupling the intersecting scanning laser to the laser carrierat a position that forces the intersecting scanning laser and theintersecting laser field to pivot about the intersecting pivot axis uponadjustment.

In embodiments, the forward-left scanning laser adjustment hardware, theforward-right scanning laser adjustment hardware, and the intersectinglaser adjustment hardware each comprise a threaded adjustment shaft, anadjustment nut, and a biasing member. The materials handling vehicle maycomprise a rear corner laser assembly coupled to a rear corner of atrailing edge of the materials handling vehicle. The materials handlingvehicle may comprise a pair of rear corner laser assemblies coupled torespective rear corners of a trailing edge of the materials handlingvehicle. The pair of rear corner laser assemblies may be configured toestablish respective rear-side laser fields extending past the leadingedge and the trailing edge of the materials handling vehicle alongrespective side edges of the materials handling vehicle.

BRIEF DESCRIPTION OF THE DRAWINGS

The embodiments set forth in the drawings are illustrative and notintended to limit the subject matter defined by the claims. Thefollowing detailed description of the illustrative embodiments can beunderstood when read in conjunction with the following drawings, wherelike structure is indicated with like reference numerals and in which:

FIG. 1 depicts a materials handling vehicle according to one or moreembodiments shown and described herein;

FIGS. 2A and 2B illustrates a bumper laser assembly according to one ormore embodiments shown and described herein;

FIG. 2C illustrates a laser carrier according to one or more embodimentsshown and described herein;

FIG. 3 depicts a materials handling vehicle and associated scanned laserfields according to one or more embodiments shown and described herein;

FIG. 4 depicts a top view of the materials handling vehicle of FIG. 3including a configuration of associated scanned laser fields accordingto one or more embodiments shown and described herein;

FIG. 5 depicts another top view of the materials handling vehicle ofFIG. 3 including another configuration of associated scanned laserfields according to one or more embodiments shown and described herein;

FIG. 6 depicts a side elevation view of the materials handling vehicleof FIG. 3; and

FIG. 7 depicts rear perspective view of the materials handling vehicleof FIG. 3.

DETAILED DESCRIPTION

The following text sets forth a broad description of numerous differentembodiments of the present disclosure. The description is to beconstrued as exemplary only and does not describe every possibleembodiment since describing every possible embodiment would beimpractical, if not impossible, and it will be understood that anyfeature, characteristic, component, composition, ingredient, product,step or methodology described herein can be deleted, combined with orsubstituted for, in whole or part, any other feature, characteristic,component, step or methodology described herein. It should be understoodthat multiple combinations of the embodiments described and shown arecontemplated and that a particular focus on one embodiment does notpreclude its inclusion in a combination of other described embodiments.Numerous alternative embodiments could also be implemented, using eithercurrent technology or technology developed after the filing date of thispatent, which would still fall within the scope of the claims.

Referring now to FIG. 1, a materials handling vehicle 10 may comprise anoperator compartment 53, a compartment tower 17, a steering mechanism S,a vehicle drive mechanism D such as a drive unit 15, a user interface U,a location module L, a navigation module N, a vehicle body, materialshandling hardware in the form of a coupling device 18, and a multi-fieldscanning tool T.

The coupling device 18 of the materials handling hardware may be, forexample and not by way of limitation, a hitch, a hook, a pintle hook,lunette eye, a ball hitch, and the like types of towing couplers. It iscontemplated that the materials handling vehicle 10 may be any type ofmaterials handling vehicle including, for example, forklifts, lifttrucks, tractors, tugger-trailer trains, etc., including, but notlimited to those powered industrial trucks identified by the UnitedStates Department of Labor, Occupational Safety & Health Administration(OSHA) in Class I—Electric Motor Rider Trucks, Class II—Electric MotorNarrow Aisle Trucks, Class III—Electric Motor Hand Trucks or Hand/RiderTrucks, Class IV—Internal Combustion Engine Trucks (Solid/CushionTires), Class V—Internal Combustion Engine Trucks (Pneumatic Tires),Class VI—Electric and Internal Combustion Engine Tractors, and ClassVII—Rough Terrain Forklift Trucks.

The multi-field scanning tool T may comprise a controller processorcommunicatively coupled to the drive unit and scanning hardware. Thesteering mechanism S, materials handling hardware, vehicle drivemechanism D, and user interface U facilitate forward movement of aleading edge the materials handling vehicle 10, and materials handled bythe materials handling vehicle 10, along a travel plane p in awarehouse.

The controller processor of the multi-field scanning tool T may beutilized to execute one or more programming instructions with respect tothe materials handling vehicle 10 and scanning hardware as describedherein. A system for implementing associated computer and software-basedmethods of the one or more programming instructions may be implementedusing a wide area network (WAN), such as an intranet or the Internet.The system may include a workstation including digital systems and otherdevices permitting connection to and navigation of the network. Variouscomponents of the system may be communicatively connected through wiredor wireless connections. The one or more programming instructions may bestored in a memory communicatively coupled to one or more controllerprocessors. The memory may be a computer-readable memory that is not anon-transitory signal through may store such signals and may beconfigured as nonvolatile computer readable medium and, as such, mayinclude random access memory (including SRAM, DRAM, and/or other typesof random access memory), flash memory, registers, compact discs (CD),digital versatile discs (DVD), magnetic disks, and/or other types ofstorage components. In some embodiments, the additional controllerhardware may comprise logic gates to perform the software instructionsas a hardware implementation. The controller processor may be configuredas, but not limited to, a general-purpose microcontroller, anapplication-specific integrated circuit, or a programmable logiccontroller.

The multi-field scanning tool T may be incorporated into larger systems,and may be able to communicate with external devices and components ofsuch systems via input/output hardware (not shown). The input/outputhardware may include any hardware and/or software for sending andreceiving data to an external device. Exemplary input/output hardwareincludes, but is not limited to, universal serial bus (USB), FireWire,Thunderbolt, local area network (LAN) port, wireless fidelity (Wi-Fi)card, WiMax card, and/or other hardware for communicating with othernetworks and/or external devices.

The multi-field scanning tool T may comprise scanning hardware in theform of, for example, a bumper laser assembly 30, a tower laser assembly50, and a rear corner laser assembly 90. The compartment tower 17 iscoupled to the body of the materials handling vehicle 10 and elevatesthe tower laser assembly 50 above the operator compartment 53 and atravel plane p of the materials handling vehicle 10. The bounds of theoperator compartment 53 of materials handling vehicles 10 contemplatedby the present disclosure are defined by those areas of the vehicle thatwould typically be occupied by the body of an operator of the vehicle.

The bumper laser assembly 30, described in greater detail further belowwith respect to FIGS. 2A-2C, is also coupled to the materials handlingvehicle 10 above the travel plane p. However, the bumper laser assembly30 is elevated at or closer to the travel plane p than the tower laserassembly 50. The rear corner laser assembly 90, described in greaterdetail further below with respect to FIG. 7, is coupled to the materialshandling vehicle 10 above the travel plane p and elevated to a similarelevation as the bumper laser assembly 30.

In embodiments, the multi-field scanning tool comprises scanninghardware establishing a scan field 52, an occupancy filter establishingan occupancy detection field 56 within the bounds of the scan field 52,and an obstacle filter establishing an obstacle detection field 54, 55within the bounds of the scan field 52. The operator compartment 53 iselevated relative to the travel plane p and includes a pair of lateraledges that are at least partially non-obstructive to the scan field ofthe multi-field scanning tool T.

The scanning hardware of the multi-field scanning tool T is configuredto generate the scan field 52 from a point of origin that is elevatedrelative to the operator compartment 53 and to expand the scan field 52such that it intersects the operator compartment 53 and extendslaterally beyond the lateral edges of the operator compartment 53 suchthat the occupancy detection field 56 established by the occupancydetection filter of the multi-field scanning tool T falls within theoperator compartment 53, and the obstacle detection field 54, 55established by the obstacle detection filter of the multi-field scanningtool T falls outside of the operator compartment 53 and terminates atthe travel plane p.

The point of origin from which the scan field 52 is generated resides onthe compartment tower 17. For example, the multi-field scanning tool Tcomprises a tower laser 51 residing on the compartment tower 17, and thetower laser 51 is oriented to project the scan field 52 downwardly intothe operator compartment 53. The scan field 52 may be projecteddownwardly into the operator compartment 53 at a downward projectionangle Ø′ relative to the compartment tower 17. Referring back to FIG. 1,the tower laser assembly 50 comprises a tower laser 51 as scanninghardware which projects a scan field 52 (FIGS. 3-6) at a downwardprojection angle Ø′ (FIG. 6) to intersect with the operator compartment53 (FIGS. 4 and 6). The downward projection angle Ø′ is between about 0degrees and about 20 degrees relative to a vertical axis of thecompartment tower 17.

The operator compartment 53 may include a leading edge 70 along anoperator platform 72 of the operator compartment 53, opposite thecompartment tower 17, and a trailing edge 74 along the operator platform72 proximate the compartment tower 17. The scan field 52 may intersectthe operator compartment 53 between the leading edge 70 and the trailingedge 74 of the operator compartment 53. The multi-field scanning tool Tmay include adjustable downward projection hardware that is configuredto adjust the downward projection angle Ø′ of the scan field 52 and alocation along the operator platform 72 at which the scan field 52intersects the operator compartment 53 between the leading edge 70 andthe trailing edge 74 of the operator compartment 53. The location alongthe operator platform 72 at which the scan field 52 intersects theoperator compartment 53 between the leading edge 70 and the trailingedge 74 of the operator compartment 53, along the operator platform 72,may be skewed towards the leading edge 70 of the operator compartment53. As a non-limiting example, the location along the operator platform72 at which the scan field 52 intersects the operator compartment 53 iswithin about 5 cm of the leading edge of the operator compartment.

In embodiments, the obstacle detection field 54, 55 extends beyond eachof the lateral edges of the operator compartment 53. The obstacledetection field 54, 55 extends at least about 0.1 m beyond each of thelateral edges of the operator compartment.

Referring to FIGS. 3 and 4, the scan field 52 comprises two obstacledetection fields 54 and 55 and an occupancy detection field 56. Themulti-field scanning tool T (FIG. 1) uses the two obstacle detectionfields 54 and 55 to identify objects along the side of, or approachingthe side of the materials handling vehicle 10. The occupancy detectionfield 56 and the obstacle detection fields 54, 55 may be contiguousportions of the scan field 52. Alternatively, the occupancy detectionfield 56 and the obstacle detection fields 54, 55 may be non-contiguousportions of the scan field 52. The occupancy detection field 56 and theobstacle detection fields 54, 55 may collectively comprise a portion ofthe scan field 52.

The multi-field scanning tool T is configured to indicate the presenceof an occupant in the occupancy detection field 56 and obstacles in theobstacle detection field 54, 55. The multi-field scanning tool T usesthe occupancy detection field 56 to identify if an operator is presentwithin the operator compartment 53. It is contemplated that theoccupancy detection field 56 may replace occupancy switches, sensors,barriers and the like. It is also contemplated that a single laser willaccomplish both the object detection functionality of the two obstacledetection fields 54 and 55 and the occupancy detection field 56.

FIGS. 2A-2C illustrate the bumper laser assembly 30 that comprises aforward-left scanning laser 31, a forward-right scanning laser 32, aintersecting scanning laser 33, a laser carrier 34, a carrier mount 35,a forward-left laser adjustment hardware 36, a forward-right laseradjustment hardware 37, and a intersecting laser adjustment hardware 38.The intersecting scanning laser 33 is coupled to the carrier mount 35.With respect to the terms “forward-left” and “forward-right” within thescope of this disclosure, the respective directional terms areconsidered with respect to a direction extending from a leading edge toa trailing edge of a component. The forward-left scanning laser 31, theforward-right scanning laser 32, and the carrier mount 35 are coupled tothe laser carrier 34. The laser carrier 34 is coupled to either thematerials handling vehicle 10 or the bumper cover 45 by two or morebumper mounts 47 to insulate the laser carrier 34 from vibration throughoperation of the materials handling vehicle 10. In other words, thebumper mounts 47 comprise, for example and not by way of limitation,rubber, springs, shock absorber materials or devices, and the like.

The multi-field bumper laser assembly 30 includes the laser carrier 34mounted to the vehicle body. The forward-left scanning laser 31 ispivotally coupled to the laser carrier 34 about a forward-left uprightpivot axis 61, the forward-right scanning laser 32 is pivotally coupledto the laser carrier 34 about a forward-right upright pivot axis 62, andthe intersecting scanning laser 33 is pivotally coupled to the lasercarrier 34 about an intersecting pivot axis 46 that intersectsrespective planes of the forward-left upright laser field 80 and theforward-right upright laser field 81.

The multi-field bumper laser assembly 30 includes the forward-leftscanning laser 31 that is positioned to direct a forward-left uprightlaser field 80 from the leading edge of the materials handling vehicle10, and the forward-right scanning laser 32 that is positioned to directa forward-right upright laser field 81 from the leading edge of thematerials handling vehicle 10. The multi-field bumper laser assembly 30further includes the intersecting scanning laser 33 that is positionedto direct an intersecting laser field 82 from the leading edge of thematerials handling vehicle 10, intersecting the forward-right uprightlaser field 81 and the forward-left upright laser field 80.

The forward-left scanning laser 31 is adjustable via the forward-leftlaser adjustment hardware 36 around the forward-left upright pivot axis61, the forward-right scanning laser 32 is adjustable via theforward-right laser adjustment hardware 37 around the forward-rightupright pivot axis 62, and the carrier mount 35, and thus theintersecting scanning laser 33, is adjustable by the intersecting laseradjustment hardware 38 around the intersecting pivot axis 46.

Thus, the multi-field bumper laser assembly 30 includes forward-leftscanning laser adjustment hardware 36 coupling the forward-left scanninglaser 31 to the laser carrier 34 at a position that forces theforward-left scanning laser 31 and the forward-left upright laser field80 to pivot about the forward-left upright pivot axis 61 uponadjustment. Further, the multi-field bumper laser assembly 30 includesforward-right scanning laser adjustment hardware 37 coupling theforward-right scanning laser 32 to the laser carrier 34 at a positionthat forces the forward-right scanning laser 32 and the forward-rightupright laser field 81 to pivot about the forward-right upright pivotaxis 62 upon adjustment. Additionally, the multi-field bumper laserassembly 30 includes intersecting laser adjustment hardware 38 couplingthe intersecting scanning laser 33 to the laser carrier 34 at a positionthat forces the intersecting scanning laser 33 and the intersectinglaser field 82 to pivot about the intersecting pivot axis 46 uponadjustment.

The forward-left scanning laser adjustment hardware 36, theforward-right scanning laser adjustment hardware 37, and theintersecting laser adjustment hardware 38 each comprise a threadedadjustment shaft 28, an adjustment nut 43, and a biasing member 44. Thebiasing member 44 may be, for example, a helical spring, a coil spring,a leaf spring, or a like biasing component. While an adjustment nut 43is described, an adjustment member configured to adjust the forward-leftscanning laser adjustment hardware 36, the forward-right scanning laseradjustment hardware 37, and the intersecting laser adjustment hardware38 about a respective pivot axis with respect to the laser carrier 34 asdescribed herein is within the scope of this disclosure.

As a non-limiting example, the forward-left laser adjustment hardware 36includes adjustable adjustment nut 43A along a front portion of athreaded adjustment shaft 28A, and an inner nut 29A disposed against afront wall of a washer 26 at a central portion of the shaft 28A. Thebiasing member 44A is disposed against a rear wall of the washer 26 anda rear wall of the laser carrier 34. Further, the washer 26 is attachedto a laser mount 21 and is protruding upwardly from the laser mount 21.While a washer 26 is described to cooperate with the forward-left laseradjustment hardware 36 to attach the adjustable laser mount 21 to thestationary laser carrier 34, other connection mechanisms to providepivotable adjustment between the forward-left scanning laser 31 and thestationary laser carrier 34 are contemplated within the scope of thisdisclosure. The forward-left scanning laser 31 is coupled to the lasermount 21. Thus, adjustment of the adjustable adjustment nut 43A willcause a compression of the biasing member 44A and will pivot the lasermount 21 with respect to the rear wall of the stationary laser carrier34 about a pivot point 23.

The forward-right laser adjustment hardware 37 includes adjustableadjustment nut 43C along a front portion of a threaded adjustment shaft28B, an inner nut 29B disposed against a front wall of a washer 27 at acentral portion of the shaft 28B. The biasing member 44C is disposedagainst a rear wall of the washer 27 and a rear wall of the lasercarrier 34. Further, the washer 27 is attached to a laser mount 22 andis protruding upwardly from the laser mount 22. While a washer 27 isdescribed to cooperate with the forward-right laser adjustment hardware37 to attach the adjustable laser mount 22 to the stationary lasercarrier 34, other connection mechanisms to provide pivotable adjustmentbetween the forward-right scanning laser 32 and the stationary lasercarrier 34 are contemplated within the scope of this disclosure. Theforward-right scanning laser 32 is coupled to the laser mount 22. Thus,adjustment of the adjustable adjustment nut 43C will cause a compressionof the biasing member 44C and will pivot the laser mount 22 with respectto the rear wall of the stationary laser carrier 34 about a pivot point24.

The intersecting laser adjustment hardware 38 includes a threadedadjustment shaft disposed between apertures defined in top walls of thelaser carrier 34 and the carrier mount 35, and an adjustable adjustmentnut 43B disposed about a top portion of the threaded adjustment shaftagainst a top portion of a top wall of the laser carrier 34. Theintersecting laser adjustment hardware 38 further includes a biasingmember 44B that is disposed about a central portion of the threadedadjustment shaft between a bottom portion of the top wall of the lasercarrier 34 and a top portion of a top wall of the carrier mount 35. Theintersecting scanning laser 33 is coupled to the carrier mount 35. Thus,adjustment of the adjustable adjustment nut 43B will cause a compressionof the biasing member 44B and will pivot the carrier mount 35 withrespect to interior side walls of the stationary laser carrier 34 aboutpivot points 25A, 25B at which the carrier mount 35 is attached to theinterior side walls of the stationary laser carrier 34.

The bumper laser assembly 30 may comprise a bumper cover 45 with aforward-left slit 39, a forward-right slit 40, and a horizontal slit 41.It is contemplated that the bumper cover 45 may be made from a robustmaterial to endure an impact with another vehicle or structure. Theforward-left scanning laser 31 projects a forward-left upright laserfield 80 (FIG. 3) through the forward-left slit 39. The forward-rightscanning laser 32 projects a forward-right upright laser field 81 (FIG.3) through the forward-right slit 40 and the intersecting scanning laser33 projects a intersecting laser field 82 (FIG. 3) through thehorizontal slit 41. The three scanned laser fields, i.e., theforward-left upright laser field 80, the forward-right upright laserfield 81, and the intersecting laser field 82, are adjustable throughmanipulation of the forward-left laser adjustment hardware 36, theforward-right laser adjustment hardware 37, and the intersecting laseradjustment hardware 38. Specifically, it is contemplated that an angle Ø(FIG. 4) between the forward-left upright laser field 80 and theforward-right upright laser field 81 may be increased, decreased, orkept the same but rotated through adjustment of the forward-left laseradjustment hardware 36 and the forward-right laser adjustment hardware37 either together or individually.

The forward-left laser adjustment hardware 36 comprises an adjustmentnut 43 and a biasing member 44 which serves to rotate the forward-leftupright laser field 80 in a sweep C-D (FIG. 4). The biasing member 44exerts a biasing force which allows for fine movement of the adjustmentnut 43 and therefore, fine adjustment of the forward-left upright laserfield 80 in the sweep C-D. Likewise, the forward-right laser adjustmenthardware 37 serves to rotate the forward-right upright laser field 81 ina sweep A-B and the intersecting laser adjustment hardware 38 serves torotate the intersecting laser field 82 in a sweep E-F (FIG. 6). Courseadjustment of the forward-left scanning laser 31, the forward-rightscanning laser 32, and the intersecting scanning laser 33 may be madethrough the coupling of the laser carrier 34 to the materials handlingvehicle 10 or the bumper cover 45.

Referring now to FIGS. 3-6, the intersecting laser field 82 is used bythe multi-field scanning tool T (FIG. 1) to identify obstacles along thetravel plane p (FIG. 1). However, it is contemplated that theintersecting laser field 82 may not detect objects (e.g., forks 11; FIG.3) protruding into the path 12 (FIG. 4) of the materials handlingvehicle 10 if they are situated above the intersecting laser field 82.The forward-left upright laser field 80 and the forward-right uprightlaser field 81 are vertically oriented scanned laser fields to identifyany objects that may be situated outside (i.e., above or below) of theintersecting laser field 82 but along the path 12 of the materialshandling vehicle 10. It is contemplated that the angle Ø (FIG. 4) may beadjusted such that the forward-left upright laser field 80 and theforward-right upright laser field 81 will accommodate the width W (FIG.4) of the materials handling vehicle 10 and/or any loads carried byand/or trailers pulled by the materials handling vehicle 10. It is alsocontemplated that the forward-left upright laser field 80 and theforward-right upright laser field 81 project forward enough to allow foradequate stopping distance should an object be detected by eitherscanned laser field. It is contemplated that because of the verticalnature of each plane, the forward-left scanning laser 31 and theforward-right scanning laser 32 do not need to be adjusted as the tires13 (FIG. 1) wear over time to maintain their projections along the path12. FIG. 5 illustrates another embodiment of the forward-left uprightlaser field 80 and the forward-right upright laser field 81 crossing infront of the materials handling vehicle 10 to provide additionalobstacle detection coverage directing along the path 12 and in front ofthe materials handling vehicle 10.

Referring to FIG. 7, the materials handling vehicle 10 may include arear corner laser assembly 90 coupled to a rear corner of a trailingedge of the materials handling vehicle 10. Further, the materialshandling vehicle 10 may include a pair of rear corner laser assemblies90 coupled to respective rear corners of a trailing edge of thematerials handling vehicle. The pair of rear corner laser assemblies 90are configured to establish respective rear-side laser fields 92extending past the leading edge and the trailing edge of the materialshandling vehicle 10 along respective side edges of the materialshandling vehicle 10.

As a non-limiting example, the rear corner laser assembly 90 isconfigured to generate respective rear-side laser fields 92 that is usedby the multi-field scanning tool T (FIG. 1) to identify obstacles alongthe travel plane p (FIG. 1). The rear corner laser assembly 90 iscoupled the trailing edge of the materials handling vehicle 10 and mayinclude a rear corner laser. For example, the pair of rear corner laserassemblies 90 may include a pair of rear corner lasers 91, 93 coupled toand protruding from respective rear corners of the trailing edge of thematerials handling vehicle 10.

The pair of rear corner lasers 91, 93 may be disposed above the travelplane p and above one or more wheels such as tires 13 of the materialshandling vehicle 10. The pair of rear corner lasers 91, 93 may beconfigured to establish respective rear-side laser fields 92 that are atleast disposed past the leading edge and the trailing edge of thematerials handling vehicle 10 along a respective side edge of thematerials handling vehicle 10. In embodiments, the pair of rear cornerlasers 91, 93 may be configured to establish a rear horizontal scanfield disposed therebetween and past the trailing edge of the materialshandling vehicle 10. The pair of rear corner lasers 91, 93 mayrespectively include adjustment hardware as described herein that isconfigured to be manipulated to adjust a respectively coupled laser 91,93 and affect a corresponding adjustment of a corresponding, respectiverear-side laser field 92.

It is contemplated that the operations of the materials handling vehicle10 can be dependent upon whether an object is detected by any of theaforementioned scanned laser fields, e.g., the forward-left uprightlaser field 80, the forward-right upright laser field 81, theintersecting laser field 82, and the scan field 52) according to anyconventional, or yet-to-be developed, materials handling vehicle controlscheme. It is further contemplated that the respective laser fields maybe subdivided so that objects detected in different portions of thesubdivided laser field will be treated or used to affect the operationsof the materials handling vehicle in different ways. For example, andnot by way of limitation, referring to FIG. 3, the forward-left uprightlaser field 80 may be subdivided into fields 64 and 71.

It is also contemplated that, although the scanned laser fields of thepresent disclosure are illustrated as substantially planar laser fields,the fields may deviate from a precisely planar configuration withoutdeparting from the scope of the present application.

It is noted that the term “sensor,” as used herein, means a device thatmeasures a physical quantity and converts it into a signal which iscorrelated to the measured value of the physical quantity. Furthermore,the term “signal” means an electrical, magnetic or optical waveform,such as current, voltage, flux, DC, AC, sinusoidal-wave,triangular-wave, square-wave, and the like, capable of being transmittedfrom one location to another.

Unless otherwise defined, all technical and scientific terms used hereinhave the same meaning as commonly understood by one of ordinary skill inthe art to which the claimed subject matter belongs. The terminologyused in the description herein is for describing particular embodimentsonly and is not intended to be limiting. As used in the specificationand appended claims, the singular forms “a,” “an,” and “the” areintended to include the plural forms as well, unless the context clearlyindicates otherwise.

Certain terminology is used in the disclosure for convenience only andis not limiting. Words like “left,” “right,” “front,” “back,” “upper,”“lower,” etc., designate directions in the drawings to which referenceis made. The terminology includes the words noted above as well asderivatives thereof and words of similar import.

It is noted that, while aspects of the present disclosure may bepresented as being performed in a particular sequence in the depictedembodiments, the functions can be performed in an alternative orderwithout departing from the scope of the present disclosure. It isfurthermore noted that one or more of these aspects can be omittedwithout departing from the scope of the embodiments described herein.

It is noted that recitations herein of a component of the presentdisclosure being “configured” or “programmed” in a particular way, toembody a particular property, or to function in a particular manner, arestructural recitations, as opposed to recitations of intended use. Morespecifically, the references herein to the manner in which a componentis “configured” or “programmed” denotes an existing physical conditionof the component and, as such, is to be taken as a definite recitationof the structural characteristics of the component.

It is noted that terms like “preferably,” “commonly,” and “typically,”when utilized herein, are not utilized to limit the scope of the claimedinvention or to imply that certain features are critical, essential, oreven important to the structure or function of the claimed invention.Rather, these terms are merely intended to identify particular aspectsof an embodiment of the present disclosure or to emphasize alternativeor additional features that may or may not be utilized in a particularembodiment of the present disclosure.

For the purposes of describing and defining the present invention it isnoted that the terms “substantially” and “approximately” are utilizedherein to represent the inherent degree of uncertainty that may beattributed to any quantitative comparison, value, measurement, or otherrepresentation. The terms “substantially” and “approximately” are alsoutilized herein to represent the degree by which a quantitativerepresentation may vary from a stated reference without resulting in achange in the basic function of the subject matter at issue.

While particular embodiments have been illustrated and described herein,it should be understood that various other changes and modifications maybe made without departing from the spirit and scope of the claimedsubject matter. Moreover, although various aspects of the claimedsubject matter have been described herein, such aspects need not beutilized in combination. It is therefore intended that the appendedclaims cover all such changes and modifications that are within thescope of the claimed subject matter.

It is noted that one or more of the following claims utilize the term“wherein” as a transitional phrase. For the purposes of defining thepresent invention, it is noted that this term is introduced in theclaims as an open-ended transitional phrase that is used to introduce arecitation of a series of characteristics of the structure and should beinterpreted in like manner as the more commonly used open-ended preambleterm “comprising.”

What is claimed is:
 1. A materials handling vehicle comprising anoperator compartment, a compartment tower, a steering mechanism,materials handling hardware, a vehicle drive mechanism, a userinterface, and a multi-field scanning tool, wherein: the steeringmechanism, materials handling hardware, vehicle drive mechanism, anduser interface facilitate forward movement of a leading edge thematerials handling vehicle, and materials handled by the materialshandling vehicle, along a travel plane in a warehouse; the multi-fieldscanning tool comprises scanning hardware establishing a scan field, anoccupancy filter establishing an occupancy detection field within thebounds of the scan field, and an obstacle filter establishing anobstacle detection field within the bounds of the scan field, a centerpoint of the occupancy detection field aligned with a center point ofthe obstacle detection field along a laterally extending horizontalaxis, the laterally extending horizontal axis perpendicular to afront-to-rear axis that intersects a front and rear of the materialshandling vehicle; the operator compartment is elevated relative to thetravel plane and comprises a pair of lateral edges that are at leastpartially non-obstructive to the scan field of the multi-field scanningtool; the scanning hardware of the multi-field scanning tool isconfigured to generate the scan field from a point of origin that iselevated relative to the operator compartment and to expand the scanfield such that it intersects the operator compartment and extendslaterally beyond the lateral edges of the operator compartment such thatthe occupancy detection field established by the occupancy detectionfilter of the multi-field scanning tool falls within the operatorcompartment, and the obstacle detection field established by theobstacle detection filter of the multi-field scanning tool falls outsideof the operator compartment and terminates at the travel plane; and themulti-field scanning tool is configured to indicate the presence of anoccupant in the occupancy detection field and obstacles in the obstacledetection field.
 2. The materials handling vehicle of claim 1, whereinthe obstacle detection field extends beyond each of the lateral edges ofthe operator compartment, and wherein the scan field comprises theoccupancy detection field disposed between and contiguous with twolaterally extending obstacle detection fields.
 3. The materials handlingvehicle of claim 1, wherein the obstacle detection field extends atleast about 0.1 m beyond each of the lateral edges of the operatorcompartment.
 4. The materials handling vehicle of claim 1, wherein themulti-field scanning tool comprises a tower laser residing on thecompartment tower.
 5. The materials handling vehicle of claim 4, whereinthe tower laser is oriented to project the scan field downwardly intothe operator compartment.
 6. The materials handling vehicle of claim 5,wherein the scan field is projected downwardly into the operatorcompartment at a downward projection angle relative to the compartmenttower.
 7. The materials handling vehicle of claim 6, wherein thedownward projection angle is between about 0 degrees and about 20degrees relative to a vertical axis of the compartment tower.
 8. Thematerials handling vehicle of claim 1, wherein the point of origin fromwhich the scan field is generated resides on the compartment tower. 9.The materials handling vehicle of claim 1, wherein: the operatorcompartment comprises a leading edge along an operator platform of theoperator compartment, opposite the compartment tower, and a trailingedge along the operator platform proximate the compartment tower; andthe scan field intersects the operator compartment, along the operatorplatform, between the leading edge and the trailing edge of the operatorcompartment.
 10. The materials handling vehicle of claim 9, wherein themulti-field scanning tool comprises adjustable downward projectionhardware that is configured to adjust a downward projection angle of thescan field and a location at which the scan field intersects theoperator compartment between the leading edge and the trailing edge ofthe operator compartment.
 11. The materials handling vehicle of claim 9,wherein: a downward projection angle of the scan field is between about0 degrees and about 20 degrees relative to a vertical axis of thecompartment tower; and the location along the operator platform at whichthe scan field intersects the operator compartment between the leadingedge and the trailing edge of the operator compartment is skewed towardsthe leading edge of the operator compartment.
 12. The materials handlingvehicle of claim 11, wherein the location along the operator platform atwhich the scan field intersects the operator compartment is within about5 cm of the leading edge of the operator compartment.
 13. The materialshandling vehicle of claim 1, wherein the occupancy detection field andthe obstacle detection field comprise contiguous portions of the scanfield.
 14. The materials handling vehicle of claim 1, wherein theoccupancy detection field and the obstacle detection field comprisenon-contiguous portions of the scan field.
 15. The materials handlingvehicle of claim 1, wherein the occupancy detection field and theobstacle detection field collectively comprise a portion of the scanfield.